A method for the manufacture of an efficient steel deoxidizer aluminum matrix composite material

ABSTRACT

A method of manufacture to provide an efficient and economical steel deoxidizer aluminum matrix composite material that is near fully dense, free of brittle intermetallic compounds and allows for deep penetration of aluminum into molten steel thus cutting unnecessary losses of this valuable metal to parasitic oxidation reactions with slag and atmosphere.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to and takes the benefit of U.S.Provisional Application Ser. No. 62/079,558 filed on Nov. 14, 2014, thecontents of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION Field of the Invention

The invention relates generally to the manufacture of compositematerials, and more particularly to a method of manufacturing analuminum matrix composite material for use as a deoxidizer in steelmaking.

Description of the Related Art

Steel deoxidation (i.e. oxygen removal from molten steel before casting)is a necessary technological step in modern steelmaking. During castingoperations, as molten steel cools down and solidifies, dissolved oxygenreacts with carbon and forms carbon monoxide (CO) gas bubbles whichbecome trapped in steel slabs or ingots resulting in porosity. Porosityis a serious defect in the manufacturing process causing a reduction inthe mechanical properties of steel and of flat-rolled steel products inparticular; therefore it is imperative that oxygen be removed from steelprior to casting.

To deoxidize molten steel, metallurgists normally introduce strongoxide-forming elements like Mn, Si and Al into the steel melt. Theseelements react with dissolved oxygen and form solid oxide particles thatare lighter than molten steel and float to the melt surface joining slagthat protects molten steel surface.

Aluminum is one of the most potent deoxidizing (deox) agents and is usedfor practically all quality flat-rolled steels which comprise about 60%of all steels produced. Aluminum is usually charged into molten steel attwo stages of steel making process. First charge, where the bulk of deoxaluminum is used, happens at tapping of electric arc furnace (EAF) orbasic oxygen furnace (BOF) into a ladle in a form of ingot or conesplaced at the bottom of an empty ladle and (or) thrown into tapped steelstream vortex. Aluminum charge carried out at tapping, in addition toits primary deox purpose, also increases throughput because deoxidationwith aluminum is quick and runs to completion while the ladle istransferred to the next operation. The second charge, where smalleramount of aluminum is usually used, is delivered into the ladle itselfat a ladle metallurgical furnace (LMF)—a special half-way facilitybetween melting furnace and caster dedicated to improving molten steelquality and bringing its composition to specification. On average 2kilograms of aluminum per ton of steel is used in the industry.

A major problem with aluminum use for steel deoxidation is that thisvaluable metal lost irreversibly. Once aluminum reacts with oxygen toform alumina or aluminum-containing oxides that float to the moltensteel surface and mix with cover slag, there are no practical ways torecover aluminum back to metallic form. Consequently, up to 4% ofprimary (reduced from bauxite ore) aluminum produced in the world islost in a non-recoverable way to steel deoxidation. However, only about30% of these losses are technologically necessary and are due toreaction of oxygen dissolved in molten steel with aluminum, the other70% are waste. To understand why, consider that in a course of steeldeoxidation, aluminum in a form of ingot or small cones is charged intoa ladle containing molten steel. Molten steel surface in the ladle iscovered with protective slag, which contains large amounts of ironoxide. Since aluminum has much lower density than molten steel (2.2 vs.7 g/cm3 at temperature), it floats to the melt surface where it istrapped in slag covering molten steel and the bulk of aluminum (70%) isexposed to and reacts with oxygen in slag's iron oxide or atmosphericair instead of oxygen dissolved in the steel and therefore is wastedinefficiently.

It should be noted, that aluminum is an extremely energy-intensive metalto make, requiring 174 GJ of electrical energy per one ton of primaryaluminum produced from bauxite ore. Luckily aluminum strongly resistsatmospheric corrosion and is easily recycled via secondary scrapsmelting—an operation that uses about 10 times less energy than primaryaluminum production from ore. Therefore, in light of global climatechange caused by carbon dioxide emissions produced to a large extent ina process of electric energy generation, unrecoverable loss of aluminumin general and unnecessary unrecoverable loss in particular is a veryserious environmental problem.

A straight forward engineering solution to the problem of aluminumfloating to steel surface during deoxidation is to join aluminum with aheavier component, so that it submerges deeper when charged into moltensteel. A logical choice for heavier component is iron or steel, since itcan make joined material heavier without contaminating steel melt.Indeed, if one considers prior art solutions to the problem, suchmaterial called ferroaluminum alloy produced via high temperaturesmelting of iron (or steel) and aluminum is offered on the market sinceapproximately 1970's—see [Deely P. D. “Ferroaluminum—Properties andUses” in Ferroalloys and Other Additives to Liquid Iron and Steel, ASTMSTP 739, J. R. Lampman and A. T. Peters, Eds, American Society forTesting of Materials, 1981, pp. 157-169]. Its practical usage insteelmaking industry demonstrated that aluminum consumption for steeldeoxidation can be cut in half. However, though technologically asuccess, ferroaluminum suffers from a few drawbacks that prevented itswide adoption in the industry. Since the alloy is produced using hightemperature smelting, it turned out expensive to manufacture due to highenergy and furnace maintenance costs, as well as high aluminum lossesdue to oxidation. Another problem associated with high processtemperature is ferroaluminum's susceptibility to crumbling during itscharging into molten steel due to thermal stresses and large brittlecomplex intermetallic phases present in the microstructure. Some ofthese intermetallic phases also react with water vapor in atmosphere, soferroaluminum alloy often crumbles to dust even during storage. Crumbleddeoxidizer is much less efficient since light crumbs are easily trappedin a slag on molten steel surface as deoxidizer is charged into moltensteel.

It is claimed that above mentioned drawbacks of ferroaluminum can beovercome by mechanically briquetting aluminum-steel particles mixtureper U.S. Pat. No. 6,350,295. Another approach to joining aluminum with aheavier component that is taught in the prior art is to melt aluminumand cast it into or around prefabricated steel shapes—see for exampleU.S. Pat. No. 4,801,328 or China patent CN21102974Y. A technique offeeding aluminum wire for deoxidation purposes is described for examplein U.S. Pat. No. 3,331,680. An innovative technology for manufacturingof aluminum deoxidizer material is disclosed in the Russian Federationpatent No 2269586.

However, though several attempts were made to develop an efficientaluminum deoxidizer material that can be economically manufactured, apractical solution acceptable to steelmaking industry is still lackingas evidenced by current industry deoxidizing practice of chargingaluminum cone and ingot into molten steel—an inefficient process thatleads to huge irreversible losses of aluminum and of energy used for itsproduction. So, there is a real practical need for a new aluminumdeoxidizer material that provides for more efficient use of aluminum insteel deoxidation compared to current practice, as well astechnologically and economically viable process for its manufacture.

SUMMARY OF THE INVENTION

The instant composite material and method of manufacture, as illustratedherein, are clearly not anticipated, rendered obvious, or even presentin any of the prior art mechanisms, either alone or in any combinationthereof. Thus the several embodiments of the instant method ofmanufacture are illustrated herein.

It is an object of this method of manufacture to provide an efficientand economical deoxidizer aluminum matrix composite material that isnear fully dense, free of brittle intermetallic compounds and allows fordeep penetration of aluminum into molten steel thus cutting unnecessarylosses of this valuable metal to parasitic oxidation reactions with slagand atmosphere.

It is another object of this method of manufacture to provide aninnovative and cost efficient technology for deoxidizer aluminum matrixcomposite manufacture based on in-situ pressure infiltration technology,meaning infiltration of a steel-aluminum or other ferrousfiller-aluminum preform porous shape by aluminum component that isin-situ present in the preform.

It is another object of this method of manufacture to provide for nearfully dense, free of brittle intermetallics and therefore non-crumblingdeoxidizer aluminum matrix composite that is safe and easy to use insteelmaking process without any equipment change or disruption toexisting manual or automated deoxidizing practices employed in theindustry.

It is still another object of this method of manufacture to provide fordeoxidizer-modifier aluminum matrix composite that contains one or moredeoxidizing and inclusion-modifying agents in addition to aluminum thusrendering the new material even more potent in deoxidizing and improvingsteel properties.

In one embodiment of the present method of manufacture, there isprovided a method for the manufacturing of an aluminum matrix compositematerial. The method includes the steps of forming a porousfree-standing preform comprised of aluminum and iron-rich component,applying heat to the free-standing preform to raise its temperatureabove the melting point of aluminum and below the melting point ofiron-rich component, and applying pressure to densify the free-standingpreform to solidify.

In yet another embodiment of the present method of manufacture, theiron-rich component of the aluminum matrix composite material is steel.The aluminum is present in the range of 10-50% of the composite materialby weight. Further, in one embodiment of the present method ofmanufacture, the aluminum is 30% of the composite material by weight.

Another embodiment of the present method of manufacture provides for afree-standing preform formed by a process of mechanical pressing,briquetting, a container, an inorganic binder or a combination of any ofthose processes.

One embodiment of the present method of manufacture provides for acertain amount of heat that is applied to the free-standing preform toraise its temperature over 661 degrees Celsius. In one embodiment, heatis applied to the free-standing preform through a process selected fromthe group including induction heating, electrical resistance furnaceheating, and organic fuel burner furnace heating. Further, anotherembodiment of the present method of manufacture provides that an amountof external pressure is applied to the free-standing preform sufficientfor a molten aluminum component to fill substantially all porosity andgaps between the iron-rich components. Yet another embodiment of thepresent method of manufacture is to provide an amount of externalpressure to the free-standing preform to densify the preform. Thepressure to densify is applied by a means of pressing in a closed die.

One embodiment of the present method of manufacture provides for theiron-rich component to be selected from a group includingferromanganese, and a mixture of steel and ferromanganese.

In yet another embodiment the free-standing preform is bound andsupported by a process selected from a group that includes mechanicalpressing, inorganic binder, a steel container, and any combinationthereof. Further, the amount of heat applied to the free-standingpreform is applied through a process that may include induction heating,electrical resistance furnace heating, and organic fuel burner furnaceheating.

One embodiment of the present method of manufacture is to provide amethod for the manufacture of an aluminum matrix composite material. Thesteps include forming a porous free-standing preform comprising of aplurality of fines of aluminum and a plurality of fines selected fromthe group consisting of: steel, ferromanganese, silicocalcium, calciumcarbide, rare earth metals, any ferroalloy other than ferromanganese.Next, applying an amount of heat to the free-standing preform sufficientto raise its temperature above the melting point of aluminum and belowthe melting point of the other components of the preform and applying anamount of pressure to densify the free-standing preform to a near fulldensity to allow for the aluminum in the free-standing preform tosolidify.

There has thus been outlined, rather broadly, the more importantfeatures of a method of manufacturing an aluminum matrix composite inorder that the detailed description thereof that follows may be betterunderstood, and in order that the present contribution to the art may bebetter appreciated. There are additional features of the compositematerial and method of manufacture that will be described hereinafterand which will form the subject matter of the claims appended hereto.

To the accomplishment of the foregoing and related ends, certainillustrative aspects are described herein in connection with thefollowing description. These aspects are indicative of the various waysin which the principles disclosed herein may be practiced and allaspects and equivalents thereof are intended to be within the scope ofthe claimed subject matter. Other advantages and novel features willbecome apparent from the following detailed description.

In this respect, before explaining at least one embodiment of the methodof manufacture of the composite material in detail, it is to beunderstood that the methodology is not limited in its application to thedetails of composite material and to the arrangements of the steps ofthe manufacturing process set forth in the following description. Themethod of manufacture is capable of other embodiments and of beingpracticed and carried out in various ways. Also, it is to be understoodthat the phraseology and terminology employed herein are for the purposeof description and should not be regarded as limiting.

These together with other objects of the composite material and methodof manufacture, along with the various features of novelty, whichcharacterize the system, are pointed out with particularity in theclaims annexed to and forming a part of this disclosure. For a betterunderstanding of the methodology, its operating advantages and thespecific objects attained by its uses, reference should be made to thedescriptive matter in which there are illustrated preferred embodimentsof the method of manufacture.

DETAILED DESCRIPTION OF THE SEVERAL EMBODIMENTS

The new steel deoxidizer material provided in the present method ofmanufacture may be best described as aluminum matrix composite.Composite materials are usually defined as comprising of discretereinforcement or filler particles or fibers that are contained in, orsurrounded by, continuous matrix material. Unlike conventional metallicalloys comprised of different metallic phases whose interactions aregoverned by thermodynamic equilibrium laws, metal matrix composites areoften referred to as engineered materials. Composites reinforcement andmatrix are joined together through an engineered manufacturing processand generally speaking do not find themselves in thermodynamicequilibrium, in many cases being chemically inert to each other—forexample refractory ceramic particles in aluminum matrix composite.

From an engineering point of view, there is a compelling reason foradding composite materials to an already wide arsenal of previouslyavailable metals and alloys. This is because composites allow toengineer materials, with microstructures and properties not achievableusing established methods of melting, casting, heat treating, cold andhot-working that rely on physicochemical processes and reactions inmetallic systems. For example, to make a deoxidizer material heavierthan aluminum, one could use smelting of aluminum with iron at a hightemperature resulting in metallurgical ferroaluminum alloy describedearlier in the text. Ferroaluminum is heavier than aluminum, butcontains large amounts of brittle and corrosion-prone intermetallicphases that make it crumble in storage or when it is charged into moltensteel. However, if steel particles could be joined with aluminum matrixinto engineered near fully dense composite material using manufacturingmethod other than high temperature smelting, the resulting material willbe much denser than aluminum, but at the same time, free of brittleintermetallic phases that reduce ferroaluminum deoxidizer efficiency dueto crumbling.

There are many technological methods for the manufacturing of metalmatrix composite materials well known to those skilled in the art. Forexample, casting is where reinforcement particles are first pre-mixedwith molten metal and then the mixture is cast into a mold. Anotherexample, powder metallurgy methods occur when solid reinforcement andmatrix particles are mixed, pressed into a shape and then sintered insolid state at high temperature. Another well-known widely appliedmethod may be generally described as pressure infiltration technology.In its custom implementation, a dry preform of reinforcement particlesis first made, heated up, placed into a die, and then molten matrixmetal is poured over the die and infiltrated into the dry preform underexternal pressure applied to the matrix metal, usually via hydraulicpress punch. Drawbacks of custom pressure infiltration technology arethat it requires a complex tooling, precise control over manufacturingparameters of each individual briquette. Also, the most criticalshortcoming is the necessity to melt and hold large batches of matrixmetal, which in the case of aluminum, leads to high losses of aluminumto dross.

New deoxidizer aluminum matrix composite material described herein ismanufactured using a pressure infiltration technology that is radicallyimproved compared to a custom one to make the technology economical toimplement and minimize losses of valuable aluminum. Unlike customtechnology, the new technology aluminum matrix infiltrant does not haveto travel from one boundary of a dry preform made of steel particlesthrough a bulk of the preform and all the way to the opposite boundaryin order to infiltrate the preform completely. Such long travel ofmolten aluminum necessitates complex and precisely machined dies toavoid aluminum bursting out under pressure, and also carries risk ofpremature aluminum cool down and incomplete preform infiltration as aresult. Instead, in the new technology, liquid aluminum has to travelonly a short distance to fill gaps between steel particles in thepreform. This is because aluminum is pre-mixed with the steel particlesat the stage of preform manufacturing—a step, which also automaticallyguarantees precise aluminum to steel weight ratio in the new compositedeoxidizer. The pre-mixed aluminum transitions to liquid state duringpreform heat-up and only travels distances comparable to average steelparticle size to fill gaps around them when the preform is squeezed in ahydraulic press die. Such technology may be called in-situ pressureinfiltration technology, because aluminum infiltrant is in-situ presentin the preform that is being infiltrated.

In a preferred embodiment, first, a porous free-standing preform shapeis formed from crushed turnings, shavings, borings or othersubstantially small pieces of aluminum mixed with crushed turnings,shavings, borings or other substantially small pieces of steel, whereinthe preferred weight fraction of aluminum is close to 30%. Formation ofthe shape is a manufacturing operation that will be known to thoseskilled in the art, and preferably achieved by mechanical pressing orbriquetting. Alternatively, the preform shape may be formed using acontainer, inorganic binder (i.e. sodium silicate), or both to make itfree-standing. Geometry of the preform shape might vary. In a preferredembodiment, the geometry may be a cylinder between 20 and 200millimeters in diameter and between 20 to 200 millimeters in height, andhaving diameter to height ratio of 1 to 1 or close to it.

Next, the preform shape is heated to a temperature that is over meltingtemperature of aluminum, but below melting temperature of steel and fora sufficient time for aluminum component to transition to liquid state.Exact heating temperature value might vary. In a preferred embodiment,the temperature range may be between 661 and 800 degrees Celsius.Possible techniques used to heat up the preform shape will be known tothose skilled in the art. In a preferred embodiment, the technique maybe induction heating, since it is extremely efficient at heatingmaterials that contain ferromagnetic components, specifically carbonsteel.

It should be noted, that though some oxidation of aluminum duringheating of the preform will take place, it will be drastically minimizedcompared to melting and holding of large aluminum batches in open airfurnaces because of brevity of the process and restricted air paths inthe preform.

Then, the heated preform shape is squeezed in an adequately tight volumeat a pressure sufficient for in-situ molten aluminum component in theshape to fill practically all porosity and gaps between steel particles,so that the composite becomes near fully dense with a density at leasthigher than 90 percent of theoretical and preferably higher than 95percent of theoretical. Pressure on the preform should be maintaineduntil the moment where the molten aluminum solidifies. Squeezingoperation may be performed using wide variety of techniques known tothose skilled in the art. In a preferred embodiment, the technique maybe pressing in a closed die mounted on a hydraulic press. The diesuitable for squeezing operation may be much less complex compared todies used in custom pressure infiltration technology. This is because incustom pressure infiltration hydraulic press punch has to drive arelatively large volume of liquid metal under high pressure for aconsiderable distance until it fully infiltrates dry preform. Hot liquidmetal under pressure may burst out of a die if it finds even a tiny gapbetween the punch and die wall. To avoid bursting, precise machining ofthe die and punch to minimize the gap is necessary, which in turn, makesit difficult to extract the punch from the die once infiltration iscomplete.

Difficulties with punch extraction often lead to further complexities indie design. For example, use of a split die may be necessary forextraction, instead of unitary cylindrical die. In the case of in-situpressure infiltration, the punch has to travel only a short distance todensify the preform, and material being pressed by the punch issemi-solid, not fully liquid like aluminum in the case of custompressure infiltration technology. This allows for much less tighter gapsbetween the punch and die walls and relieves punch extraction problem,so that a simple cylindrical unitary die may be used.

In alternative embodiments of the method of manufacture, weightfractions of aluminum in the free-standing porous shape may vary between10% and 50%.

In another alternative embodiment of the method of manufacture, theporous free-standing preform shape is formed from crushed turnings,shavings, borings or other substantially small pieces of aluminum mixedwith substantially small pieces of ferromanganese, wherein the weightfraction of aluminum is close to 25%. The rest of the process steps,including shape heating and heated shape squeezing are substantially thesame. A rational for substituting steel with ferromanganese, is that onone hand, it is known to those skilled in the art that combined effectof aluminum and manganese as deoxidizers is stronger than of eitherelement separately. On the other hand, ferromanganese may serve the samefunctions as steel as far as making aluminum-containing deoxidizerheavier and providing efficient induction coupling during inductionheating of the porous free-standing preform shape.

In other alternative embodiments of the method of manufacture, some ofthe steel and aluminum in the free-standing porous preform shape may bereplaced by additions useful in the steelmaking process, such assilicocalcium, calcium carbide, rare earth metals and other usefuladditions. Such additions may help deoxidize steel even better thanaluminum alone, or modify shape and size of oxides and othernon-metallic particles suspended in molten steel, making them smallerand more compact, thus improving appearance and mechanical properties ofa final flat rolled steel product.

In a preferred embodiment, the new steel deoxidizer aluminum matrixcomposite material manufactured as described in the preferred embodimentabove is used to deoxidize steel at the stage of EAF or BOF tapping intoa ladle as direct replacement of aluminum ingot or cone. Not to be heldto a particular theory, weight ratio of the deoxidizer compositematerial to weight of aluminum ingot or cone it replaces may beestimated as 1.66 to 1 based on the following considerations. It isknown from past industrial practice that non-crumbled ferroaluminumcontaining close to 30% aluminum by weight saves about 50% of aluminumcompared to deoxidation using ingot or cone. Therefore, each kilogram ofaluminum ingot or cone may be replaced by 0.5 kilogram of aluminumcontained in ferroaluminum, or in case of the present method ofmanufacture in deoxidizer aluminum matrix composite. For a preferredweight ratio of aluminum to steel of 30 to 70, one may calculate thetotal weight of new deoxidizer replacing one kilogram of aluminum ingotor cone as 0.5 kilogram multiplied by 100 and divided by 30, whichequals 1.66 kilogram.

While the above description contains many specificities, these shouldnot be construed as limitations on the scope of the method ofmanufacture, but rather as an exemplification of preferred embodimentsthereof. Many other variations are possible. Accordingly, the scope ofthe method of manufacture should be determined not by the embodimentsillustrated, but by the appended claims and their legal equivalents.

What is claimed is:
 1. A method for the manufacture of a steeldeoxidizer aluminum matrix composite material comprising the steps of:forming a porous free-standing preform, wherein the free-standingpreform is comprised of aluminum and an iron-rich component; applying aquantity of heat to the free-standing preform to raise the temperatureof the free-standing preform above the melting point of aluminum andbelow the melting point of the iron-rich component; and applying aquantity of pressure to densify the free-standing preform to a near fulldensity and to allow for the aluminum in the free-standing preform tosolidify.
 2. The method for the manufacture of a steel deoxidizeraluminum matrix composite material of claim 1, wherein the iron-richcomponent is steel.
 3. The method for the manufacture of a steeldeoxidizer aluminum matrix composite material of claim 1, whereinaluminum is present in the range of ten to fifty percent of thecomposite material by weight.
 4. The method for the manufacture of asteel deoxidizer aluminum matrix composite material of claim 3, whereinaluminum is thirty percent of the composite material by weight.
 5. Themethod for the manufacture of a steel deoxidizer aluminum matrixcomposite material of claim 1, wherein the free-standing preform isformed by a process selected from the group consisting of: mechanicalpressing, briquetting, a container, an inorganic binder, and anycombination thereof.
 6. The method for the manufacture of a steeldeoxidizer aluminum matrix composite material of claim 1, wherein thequantity of heat applied to the free-standing preform is sufficient toraise its temperature over six hundred sixty one degrees Celsius.
 7. Themethod for the manufacture of a steel deoxidizer aluminum matrixcomposite material of claim 1, wherein the quantity of heat applied tothe free-standing preform is through a process selected from the groupconsisting of: induction heating, electrical resistance furnace heating,and organic fuel burner furnace heating, and any combination thereof. 8.The method for the manufacture of a steel deoxidizer aluminum matrixcomposite material of claim 1, wherein the quantity of external pressureapplied to the free-standing preform is sufficient for a molten aluminumcomponent to fill porosity and gaps between the iron-rich components. 9.The method for the manufacture of a steel deoxidizer aluminum matrixcomposite material of claim 1, wherein the quantity of external pressureto densify the preform is applied by means of pressing in a closed die.10. The method for the manufacture of a steel deoxidizer aluminum matrixcomposite material of claim 1, wherein the iron-rich component isselected from the group consisting of: ferromanganese, and a mixture ofsteel and ferromanganese.
 11. The method for the manufacture of a steeldeoxidizer aluminum matrix composite material of claim 10, wherein thefree-standing preform is bound and supported by a process selected fromthe group consisting of: mechanical pressing, inorganic binder, a steelcontainer, and any combination thereof.
 12. The method for themanufacture of a steel deoxidizer aluminum matrix composite material ofclaim 11, wherein the quantity of heat to the free-standing preformapplied is through a process selected from the group consisting of:induction heating, electrical resistance furnace heating, and organicfuel burner furnace heating, and any combination thereof.
 13. A methodfor the manufacture of a steel deoxidizer and inclusion modifieraluminum matrix composite material comprising the steps of: forming aporous free-standing preform, wherein the free-standing preform iscomprised of a plurality of fines of aluminum and a plurality of finesselected from the group consisting of: steel, ferromanganese,silicocalcium, calcium carbide, rare earth metals, any ferroalloy otherthan ferromanganese, and any combination thereof; applying a quantity ofheat to the free-standing preform to raise the temperature of thefree-standing preform above the melting point of aluminum and below themelting point of other components of the free-standing preform; andapplying a quantity of pressure to densify the free-standing preform toa near full density and to allow for the aluminum in the free-standingpreform to solidify.
 14. The method for the manufacture of a steeldeoxidizer aluminum matrix composite material of claim 13, whereinaluminum is present in the range of ten to fifty percent of thecomposite material by weight.
 15. The method for the manufacture of asteel deoxidizer aluminum matrix composite material of claim 13, whereinaluminum is thirty percent of the composite material by weight.
 16. Themethod for the manufacture of a steel deoxidizer aluminum matrixcomposite material of claim 13, wherein the free-standing preform isformed by a process selected from the group consisting of: mechanicalpressing, briquetting, a container, an inorganic binder, and anycombination thereof.
 17. The method for the manufacture of a steeldeoxidizer aluminum matrix composite material of claim 13, wherein thequantity of heat applied to the free-standing preform is sufficient toraise its temperature over six hundred sixty one degrees Celsius. 18.The method for the manufacture of a steel deoxidizer aluminum matrixcomposite material of claim 13, wherein the quantity of heat to thefree-standing preform applied is through a process selected from thegroup consisting of: induction heating, electrical resistance furnaceheating, and organic fuel burner furnace heating, and any combinationthereof.
 19. The method for the manufacture of a steel deoxidizeraluminum matrix composite material of claim 13, wherein the quantity ofexternal pressure applied to the free-standing preform is sufficient fora molten aluminum component to fill porosity and gaps between theiron-rich components.
 20. The method for the manufacture of a steeldeoxidizer aluminum matrix composite material of claim 13, wherein thequantity of external pressure to densify the preform is applied by meansof pressing in a closed die.